Clearly your loopback with audio interface only and audio interface + amplifier can give consistent results, which means that your setup is doing fine.
But after inserting the microphone,
the room, and speaker into the recording chain, spurious things pop up.
If we go back to doing ordinary Sweeps, Longer sweeps are better than shorter ones. But this needs a consistently quiet environment eg. hemi/anechoic chambers.
In an ordinary room/office, transient noise is a real deal breaker. One way of getting around this is using multiple shorter sweeps, so that noisier ones can be discarded.
Or in REW's case,
averaged
REW allows multiple sweeps to be averaged, although best results are generally obtained by using single, longer sweeps rather than multiple, shorter sweeps......If Repetitions is more than 1 REW uses synchronous pre-averaging, capturing the selected number of sweeps per measurement and averaging the results to reduce the effects of noise and interference. The pre-averaging can improve S/N by almost 3 dB for each doubling of the number of sweeps. Averaging can be useful if the measurements are contaminated by interference tones, whether electrical or acoustic, as they typically will not add coherently in the averaging and hence will be suppressed by the process.
For frequency response I tend to take 1M samples, which takes me ~12 seconds at a sample of 88.2KHz,
But for distortion measurements in an ordinary untreated room/office I prefer to take 256K x4 repetitions, which takes the same amount of time, but is better at reducing spurious noises.
Here's 3 measurements in FSAF mode with pink noise lasting 5 seconds, the mic 1.2m from the ground/ceiling, and 31.6cm from the driver.
These are taken different times of day. And, with one in the nearfield, to minimize environmental noise.
Clearly the effects of the room and time of day are affecting these measurements.
It would appear to me that FSAF can suffer because there's no averaging. The shortest measurement is a 5 second measurement with noise.
If your measurement is a longer measurement, or with music,
@dcibel Could it be that there something in the environment that is causing the noise?